Semi-liquid metal processing and sensing device and method of using same

ABSTRACT

A semi-liquid metal processing and sensing device comprising a crucible that is at least partially encircled by at least one induction coil. The one or more induction coils can be water cooled. The one or more induction coils can be designed to generate a variable power and/or variable frequency magnetic field which can be modulated to control the cooling of a molten metal charge in the crucible from the liquidus temperature to a selected heat content, resistivity and/or viscosity. The magnetic field can be designed to induce toroidal agitation of the metal charge in the crucible. The semi-liquid condition is sensed and can be actively controlled by the induction power supply via real time or non-real time analysis of electrical feedback signals that are obtained from the induction coil.

The present invention is a continuation of U.S. patent application Ser.No. 12/680,652 filed Jun. 8, 2010, which in turn claims priority onInternational Application No. PCT/US2008/079465 filed Oct. 10, 2008,which in turn claims priority on U.S. Provisional Patent ApplicationSer. No. 60/979,511 filed Oct. 12, 2007, which is incorporated in itsentirety by reference herein.

The invention relates generally to a device and method for processingmolten and/or semi-molten metal; particularly to a device and method forat least partially monitoring and/or controlling the heating, cooling,and/or stirring of molten and/or semi-molten material; more particularlyto a device and method for at least partially monitoring and/orcontrolling the heating, cooling, and/or stirring of molten and/orsemi-molten material and sensing the condition of the molten and/orsemi-molten material; and still more particularly to a device and methodfor at least partially monitoring and/or controlling the heating,cooling, and/or stirring of molten and/or semi-molten material andsensing the condition of the molten and/or semi-molten material, andproviding an arrangement to transfer the molten and/or semi-moltenmaterial to a forming device.

BACKGROUND OF THE INVENTION

Metal processing and forming is an important industrial process. It isoften desirable to form or cast a metal product from a metal that is ina molten state that is not entirely liquid. At the same time, it isdesirable to control selected properties of the material, such asviscosity. One known process of controlling the material propertiesconsists of shearing a molten alloy with a stirring apparatus, while atthe same time cooling the metal through the semi-solid temperature rangeof the alloy (i.e., a temperature ranging between the liquidustemperature and the solidus temperature) during which time the materialwill have a varying solids fraction (fs), but will have a consistencymore solid than liquid. The liquidus temperature is the minimumtemperature at which all components of a mixture (such as a metal alloy)can be in a liquid state. Below the liquidus temperature, the mixturewill be partly or entirely solid. The solidus temperature is the maximumtemperature at which all components of a mixture (such as a metal alloy)can be in a solid state. Above the solidus temperature, some or all ofthe mixture will be in a liquid state.

This type of metal processing results in initiation nucleation in themixture when the melt temperature of the mixture has dropped below theliquidus temperature, thereby preventing the normally-occurringformation of a dendritic (i.e., needle-like, crystalline structure inthe material). During this type of metal processing and when thesemi-solid material is at a specific solids fraction, themulti-constituent alloy material has a structure consisting of solid,spheroidal “α-particles” (i.e., solid particles having a higher meltingpoint primary constituent) that are surrounded by a eutectic liquid(i.e., a liquid comprising lower melting point constituents). As such,during the processing of the mixture, the semi-solid material,hereinafter referred to as “SSM,” has a viscosity which enables themixture to be handled as a semi-rigid mass. Such semi-rigid mass of themixture can be injected into a mold under conditions of laminar flow,unlike the turbulent flow usually characterizing a conventional fullymolten alloy forming and injection process.

Injecting SSM into a mold under laminar flow can eliminate many commondefects associated with a conventional molten metal process forproducing die castings, permanent mold castings and other castingmethods. These defects include shrinkage porosity, formation of oxides,and gas porosity. Each of these defects can cause reduced mechanicalproperties of the formed mixture, such as lowered strength, reducedfatigue life, and/or reduced ability of the castings to satisfactorilybe heat treated, which is typically employed to optimize strength andelongation of the casted product.

Another beneficial feature of a process that includes the shearing of amolten alloy is that after processing the SSM, the material can beallowed to fully solidify, and upon subsequent re-heating, the materialretains the spheroidal “α-particle” SSM structure throughout itssemi-solid temperature range. This latter reheating process has been acommon and preferred practice due to the ability to create metal stockhaving the SSM structure through a high-volume bar casting operation.The bars can be readily shipped to a production facility, cut to aselected size, and then re-heated to a semi-solid condition inpreparation for a forming or casting operation. However, this process isexpensive due to costs associated with equipment used for reheating theSSM and casting the processed bar stock, as well as the inability torecycle processed material and scrap on-site while retaining the SSMstructure.

Melting, cooling, and processing of SSM material on-site from standardraw metal stock can result in economies in both equipment and materialrecycling compared to the reheating process, in large part becauseexpensive re-heating equipment is not required, and large quantities ofmaterial are not maintained in process-material that can be renderedunusable if an interruption of the heating or forming process shouldoccur. This standard metal production process is performed with standardfurnaces and molten metal transfer equipment. Scrapped metal can bereadily recycled and reprocessed into an SSM condition on-site, asneeded. Some cost is incurred for an on-site processing unit, but thisis typically significantly less than the total cost of all thespecialized equipment needed for the reheating process.

In both the reheating process and a conventional production process, thegoal is to create a selected microstructure in the finished metal. Asignificant benefit of the SSM process and subsequent forming of thematerial into finished products is the ability for the viscous SSMmaterial to flow in a laminar fashion into a mold, which minimizes theoccurrence of defects.

Benefits from this process include improved mechanical properties andfatigue life, based on the minimization of oxides, gas porosity andshrinkage porosity. Safety-critical and pressure-sensitive componentsare prime candidates for these SSM forming processes.

Conventionally, the desired SSM condition is determined by thetemperature of the molten metal charge using a thermocouple. Thethermocouple is either immersed in the material, or embedded in thecontainer holding the material. An alternate method is to retrieve asample of material, and cut or knead the material with a spatula to geta “feel” for the viscosity. However, such alternate methods areimprecise, destructive, and involve a separate process step that is not“in line” with the essential melting and casting process. Thethermocouple has limitations because it is effectively sacrificial, andcan degrade, erode, or become fouled during use.

Other methods of process control are performed on a time basis,programmed via an algorithm that takes into account only the initialmolten metal temperature through thermocouple sensing, and the knownthermal characteristics of the metal alloy. This control method isunreliable since it does not take into account all variables, such ascontainer temperatures and ambient temperatures. Existing methods alsodo not enable continuous monitoring of the condition of the SSM materialthroughout the charging, processing, delivery or transfer steps of theforming process.

A semi-liquid material, hereinafter referred to as “SLM,” also has atemperature ranging between the liquidus temperature and the solidustemperature, but with a consistency more liquid than solid. SLM is alsoutilized for forming and casting operations. Existing SLM methods alsosuffer from limitations. Such methods do not account for irregularforming cycle times caused by downstream machine interruptions, operatorinterruptions, or short-term maintenance interruptions. If a standardcooling cycle is delayed or interrupted, the SLM charge must bescrapped, and another metal charge must be processed when the machineinterruption has been resolved. This can result in wasted material, andwith attendant increased costs. Also, existing SLM methods are unable tocontrol the SLM process in a manner that ensures that the temperatureand viscosity conditions of the SLM charge are consistently the same foreach metal charge.

In view of the current state of the art, there is a need for anapparatus and method that overcomes the past deficiencies associatedwith processing SSM/SLM. In particular, there is a need for an apparatusand method that can be used to control the SSM/SLM process in a mannerthat ensures that the temperature and/or viscosity conditions of theSSM/SLM charge are consistently the same for each metal charge, andwhich apparatus and method allows for continuous monitoring of thecondition of the SSM/SLM material throughout the charging, processing,and delivery or transfer steps of a forming process.

SUMMARY OF THE INVENTION

The present invention is directed to a semi-liquid metal (SLM) and/orsemi-solid metal (SSM) processing and sensing device that overcomes thepast deficiencies associated with processing SSM/SLM. As used herein,the terms SSM and SLM will be used interchangeably, and both refer to ametal or metal alloy that is at a temperature ranging between theliquidus temperature and the solidus temperature of the metal or metalalloy.

In one non-limiting embodiment of the invention, there is provided aprocessing and sensing device that includes a crucible or containersystem that is at least partially encircled by at least one inductioncoil. The semi-liquid condition of the metal or metal alloy in thecrucible or container system can be designed to be sensed and/or beactively controlled by the induction power supply via real time ornon-real time analysis of electrical feedback signals that are obtainedfrom the at least one induction coil. In one non-limiting aspect of thisembodiment, the one or more induction heating coils can be water-cooledsolenoid induction coils; however, this is not required. In anotherand/or alternative non-limiting aspect of this embodiment, the one ormore induction coils can be designed to generate a variable power and/orvariable frequency magnetic field which can be modulated to control thecooling of a molten metal charge in the crucible or container systemfrom the liquid, molten metal temperature to a selected heat content,resistivity and/or viscosity below the liquidus temperature of thematerial. In still another and/or alternative non-limiting aspect ofthis embodiment, the one or more induction coils can be designed tocreate a magnetic field that induces toroidal agitation of the metalcharge in the crucible or container system. In yet another and/oralternative non-limiting aspect of this embodiment, the one or moreinduction coils can be designed to create a single zone of heatingand/or stirring in the crucible or container system, or multipleinduction coils can be used to create multiple zones of heating and/orstirring in the crucible or container system. Several prior artarrangements of the apparatuses and method that can be used in thepresent invention to process metals and metal alloys between theliquidus temperature and the solidus temperature of the metal or metalalloy are disclosed in U.S. Pat. Nos. 7,216,690; 7,169,350; 7,132,077;6,991,970; 6,932,938; 6,796,362; 6,637,927; 6,443,216; 6,432,160;6,402,367; 6,399,017; 5,219,018; and 4,434,837; and United StatesPublication No. 2007/0187060; all of which are fully incorporated hereinby reference. For example, U.S. Pat. Nos. 7,169,350; 6,991,970; and6,432,160 disclose an apparatus and method for producing an “on-demand”semi-solid material for use in a casting process. The apparatus caninclude various stations which have the requisite components andstructural arrangements that are to be used as part of the process. Theapparatus and method includes the use of electromagnetic stirring andvarious temperature control and cooling control techniques and anapparatus that is used to facilitate in the production of the semi-solidmaterial within a comparatively short cycle time. The apparatus andmethod also includes structural arrangements and techniques that areused to discharge the semi-solid material directly into a castingmachine shot sleeve. The apparatus and method disclosed in U.S. Pat.Nos. 7,169,350; 6,991,970; and 6,432,160 can be fully or partially usedin the present invention. U.S. Pat. Nos. 7,132,077; 6,932,938;6,796,362; 6,443,216; and 6,399,017 disclose a crucible or containersystem for holding metals and metal alloys between the liquidustemperature and the solidus temperature of the metal or metal alloy. Thecrucible or container system can include a mechanical or electromagneticejection system for discharging the processed metal or metal alloy fromthe crucible or container system. The crucible or container system caninclude a cooling arrangement and/or insulation arrangement. Thecrucible or container system disclosed in U.S. Pat. Nos. 7,132,077;6,932,938; 6,796,362; 6,443,216; and 6,399,017 can be fully or partiallyused in the present invention. U.S. Pat. Nos. 7,169,350; 6,991,970;6,637,927; 6,432,160; 6,402,367; 5,219,018; and 4,434,837 disclose anapparatus and method for mechanical or electromagnetic stirring ofmetals and metal alloys between the liquidus temperature and the solidustemperature of the metal or metal alloy that are contained in a crucibleor container system. The stirring arrangements disclosed in U.S. Pat.Nos. 7,169,350; 6,991,970; 6,637,927; 6,432,160; 6,402,367; 5,219,018;and 4,434,837 can be fully or partially used in the present invention.

In another and/or alternative non-limiting embodiment of the invention,there is provided a processing and sensing device that includes the useof a crucible or container system that is at least partially encircledby at least one induction coil and which the temperature of the metal ormetal alloy in the crucible can be determined via real time or non-realtime analysis of electrical feedback signals that are obtained from theat least one induction coil. In such an arrangement, the use of priorart thermocouples can be eliminated. As stated above, prior artthermocouples were contact thermocouples positioned in or about acrucible or container system. Such prior art thermocouples had atendency to erode over time, thus providing inaccurate readings thatcould result in improper temperatures in the crucible or containersystem. Additionally, the maintenance of these prior art thermocouplescould be difficult, time consuming, and costly.

In another and/or alternative non-limiting embodiment of the invention,there is provided a processing and sensing device that includes the useof a crucible or container system that is at least partially encircledby at least one induction coil and which the induction coil can bedesigned to be sensed and be actively controlled by the induction powersupply via real time or non-real time analysis of electrical feedbacksignals that are obtained from the at least one induction coil. As such,the prior art method of control of the process of heating, coolingand/or dispensing a metal or metal alloy from a crucible or containersystem based on a predetermined time basis, and/or a preprogrammedalgorithm which only takes into account the initial metal or metal alloytemperature as such metal or metal alloy is initially placed in thecrucible or container system is eliminated by the process of the presentinvention. Such prior art control process are unreliable since the priorart process does not and cannot take into account all of the variablesassociated with the metal or metal alloy in the crucible or containersystem (e.g., container temperature, ambient temperature, etc.). Thecontrol system in accordance with the present invention has the abilityto constantly or periodically monitor the temperature of the metal ormetal alloy in the crucible or container system and thereby providerealtime or near realtime control of the temperature of the metal ormetal alloy in the crucible or container system throughout the charging,processing and delivery/transfer stages of the metal or metal alloy.Prior art control systems have no way to account for irregular formingcycle times caused by downstream machine interruptions, operatorinterruptions or short-term maintenance interruptions. As such, if thestandard cooling cycle is delayed or interrupted, the metal or metalalloy in the crucible or container system will likely have to bescrapped and another charge processed when the machine is ready torestart casting. The control system in accordance with the presentinvention has the ability to monitor and maintain the temperature of themetal or metal alloy in the crucible or container system during suchinterruptions so that the metal or metal alloy does not have to bescrapped and that the metal or metal alloy is delivered to the castand/or shot sleeve at the desired temperature. Prior art control systemshave no satisfactory way to control the temperature of the metal ormetal alloy in the crucible or container system so as to guarantee thatthe condition/consistency/viscosity of the metal or metal alloydispensed from the crucible or container system has the same physicalcharacteristics (e.g., temperature, viscosity, etc.). The control systemin accordance with the present invention has the ability to monitor andmaintain the physical characteristics of the metal or metal alloy eachtime the metal or metal alloy is dispensed from the crucible orcontainer system. As such, the control system in accordance with thepresent invention overcomes many of the deficiencies of prior artcontrol systems and to provide a control system that is more economical,repeatable and robust than it is practiced currently in the castingindustry.

In one non-limiting specific arrangement of the present invention, thereis provided a control system that includes a generator (i.e., processingdevice), which control system is designed to 1) periodically orcontinually sense the condition of a metal or metal alloy in thegenerator from the time the metal or metal alloy is introduced in thegenerator to the time the metal or metal alloy is poured out of orotherwise expelled from the generator to a receptacle of a formingmachine (i.e., shot sleeve, sprue, funnel, etc.), 2) control of thecooling, heating and/or stirring (for thermal homogeneity) of the metalor metal alloy in the generator so as to ensure that the metal or metalalloy delivered to the forming machine is of repeatable, consistentthermal, micro-structural and viscous condition shot-to-shot, and/or 3)provide a continuous means for transfer of the material (e.g., after themolten metal or metal alloy is introduced into the generator) from thegenerator to the forming machine. The generator can be uncoupled toeither the molten metal source and/or forming machine receptacle;however, this is not required; however, it can be appreciated that thegenerator is physically coupled to the molten metal source and/or theforming machine receptacle. In one non-limiting design, the generatorincludes a generally cylindrical chamber or crucible (e.g., graphite,ceramic/refractory, combination of metal and graphite and/or ceramic,etc.) which holds the molten metal (e.g., molten aluminum, moltenaluminum alloy, etc.) that is initially poured or otherwise insertedinto the generator. The generally cylindrical chamber or crucible can beat least partially surrounded on the outside within about 0.01-1 inch ofthe outer surface of the generally cylindrical chamber or crucible by asolenoid induction coil. This coil is generally fixed at a generallyuniform distance from the outer surface of the generally cylindricalchamber or crucible with refractory spacers so as to insure a centeringof the generally cylindrical chamber or crucible within the inductioncoil; however, this is not required. The wound coil height is generallysufficient to enclose the entire generally cylindrical chamber orcrucible, and can include an extension beyond the length of the crucibleat the top and/or bottom of the generally cylindrical chamber orcrucible a distance of up to one third of the generally cylindricalchamber or crucible height (e.g., for a 6 inch high crucible, the totallength of the induction coil could be up to about 10 inches long). Thisover extension of the induction coil, when used, facilitates in 1) theeven heating of the generally cylindrical chamber or crucible at the topand bottom of the generally cylindrical chamber or crucible, and/or 2)the proper stirring of the metal or metal inside the generallycylindrical chamber or crucible by the electromagnetic force of theinduction field generated by the induction coil. The annular spacebetween the induction coil and the generally cylindrical chamber orcrucible can be at least partially filled either with rammed/compacteddry refractory material, mica paper, or cast into place within theinduction coil using a refractory type cement; however, this is notrequired. The purpose of the rammed/compacted dry refractory material,mica paper, or cast refractory type cement, when used, is to provideintimate contact between the induction coil and the generallycylindrical chamber or crucible. This intimate contact, when created,enables heat extraction from the generally cylindrical chamber orcrucible to the water-cooled induction coil, while at the same timeheating of the metal or metal alloy in the generally cylindrical chamberor crucible can be provided by the induction coil. The total effect ofthe cooling capacity of the induction coil and the heating capacity ofthe induction coil is to provide a fast response method to control thetemperature, viscosity and/or fraction solid (f_(s)) content of themetal or metal alloy in the generally cylindrical chamber or crucible.The ability to control the cooling rate and the temperature of the metalor metal alloy in the generally cylindrical chamber or crucible enablesthe delivery of a metal or metal alloy charge in a repeatable fashion toa forming device, even in the event of a cycle delay or productioninterruption. The entire crucible and coil assembly can be containedinside a protective, electrically non-conductive housing for safety andprotection of the equipment; however, this is not required. Theinduction coil is generally powered by a variable frequency power supply(e.g., 10-10000 Hz, etc.). This power supply can be designed to operatein a single frequency range or a simultaneous, multiple frequency modeto enhance toroidal stirring for homogeneity and/or to better controlthe heating/cooling process. The control system for the generator can bedesigned to 1) sense the condition of the molten/semi-solid/liquid metalor metal alloy charge in the generator, and/or 2) control the heatingand/or cooling rates of the metal or metal alloy charge in the generatorbased on control signal from the induction coil. In one non-limitingarrangement, a feedback or control signal is obtained from the inductioncoil that is doing the heating and cooling. This signal can be also oralternatively be obtained from a second, unpowered solenoid coil inclose proximity to the metal or metal alloy charge in the generator. Assuch, the feedback or control signal can be obtained from direct contactwith the induction coil or indirectly (i.e., a non-contact source) fromthe induction coil. For instance, the control board of the inductionpower unit can be equipped with signal conditioning that monitors (e.g.,continuously, periodically) the load on the induction coil. This load isthe induction coil and the conductive material inside the inductioncoil. The conductive material can be considered the metal or metal alloycharge in the generator and the generator itself if the generatormaterial is conductive (e.g., graphite, metal, etc.). Electricallysensed changes in the load are due to thermal changes and metallurgicalchanges in the metal or metal alloy charge in the generator as the metalor metal alloy cools down and heats up. One of the changes of electricalparameters that can be sensed is a resistivity change in the metal ormetal alloy charge in the generator which produces a change in theinduction coil voltage. As can be appreciated, other or additionalelectrical parameters can be sensed for purposes of monitoring and/orcontrolling the operation of the generator. These one or more sensedelectrical parameters can be used to at least partially determine,monitor and/or control a property of the metal charge includes, but isnot limited to, a load resistance inside a region that is at leastpartially encircled by the induction coil, a resistivity of the metalcharge, a temperature of the metal charge, a solid fraction of the metalcharge, and/or a liquid fraction of the metal charge. As can beappreciated, other properties of the metal charge can be monitored,determined and/or controlled by the sensing of one or more electricalparameters. This voltage change can be used as a feedback signal tocontrol the heating and cooling process for the metal or metal alloycharge in the generator. Using various signal conditioning features inthe induction control system, this voltage signal and/or other availablesignals reflecting the condition of the metal or metal alloy charge inthe generator can be used to modulate and control the physical processof cooling, heating and/or holding the temperature metal or metal alloycharge in the generator. The induction control system can be designed toprovide the signal and track the signal even when modulating the poweroutput. Therefore the control of the heating and cooling process of themetal or metal alloy charge in the generator can be 1) continuous, 2)non-contact (i.e., no thermocouple required in the molten metal or metalalloy or crucible wall), 3) able to be adjusted to a desired operatingpoint, and/or 4) able to deliver the metal or metal alloy charge in thegenerator to the forming station. The heating and cooling control systemfor the metal or metal alloy charge in the generator can be used inconjunction with one of the other SSM/SLM production methods. Forexample, some other control system can be used to initiate thenucleation process of the metal or metal alloy and then the processcontrol can be used to control the heating and cooling of the metal ormetal alloy in the generator to insure a homogeneous temperature for themetal or metal alloy. The control system can also be used to obtain andthen maintain, if necessary, a desired temperature of the metal or metalalloy in the generator to the point that the metal or metal alloy isdelivered to the forming station. Depending on the design of the formingmachine and its charge receptacle, the generator can be designed to betilted so as to pour a charge into a vertically or horizontally orientedshot sleeve. The generator and the connecting induction power leads canbe affixed to a multi-axis (e.g., typically 3 or more axes)robot/mechanical arm; however, this is not required. This robot arm,when used, can have sufficient motion to move the generator to aposition to accept a molten metal charge (e.g., from a ladle, metalpump, dosing furnace, etc.). The robot arm can be designed to move thegenerator and the connecting induction power leads to an intermediateposition to create the SLM structure at a separate nucleation device orto create the SLM structure by the generator internally in transit tothe delivery point at the forming station. The robot arm can then bedesigned to move the generator and the connecting induction power leadsto a forming station wherein the generator is tilted to pour or slideout of the metal or metal alloy charge or actively is engaged via aplunger/piston to inject the metal or metal alloy charge into theforming or injection chamber of the forming machine. The induction powersupply can either be an integral part of the delivery unit or placedseparately, remote from the robot arm and process area. As can beappreciated, the generator can be part of a fully coupled unit. In suchan arrangement, the generator accepts a metered charge though a heatedtransfer tube directly from a dosing furnace or molten metal pump. Themolten metal passes through the generator wherein the charge is cooledand stirred. The induction coil can be a single solenoid powered by asingle frequency generator or triple-wound independent coil supplied bya three phase frequency induction generator to enhance metal movementthrough the generator. The charge would be held in the generator sectionat a controlled condition. When the cycle calls for metal for injection,the metal supply device (pump or dosing unit) is actuated and thegenerator proceeds to move the charge along the heated conduit into theforming/injection chamber as a new volume of molten metal is introducedinto the generator. Some of the non-limiting features of the controlsystem are:

-   -   The process equipment and method can be designed to continuously        or intermediately sense the degree of semi-solid/liquid material        that is present in a volume of material in-process without        physical contact with the metal charge.    -   The containment device or crucible can be made from graphite.    -   The containment device or crucible can be made from stainless        steel alloys and lined with graphite, silicon nitride, and/or        other refractory ceramic materials.    -   The containment device or crucible can be a ceramic refractory.    -   The containment device or crucible can be affixed within the        solenoid heating/cooling coil rammed with dry refractory        material.    -   The containment device or crucible can be affixed within the        solenoid heating/cooling coil by means of a cast-in refractory        cement.    -   The solenoid induction coil surrounding the crucible can serve        as a cooling device.    -   The solenoid induction coil surrounding the crucible can serve        as a heating device.    -   The solenoid induction coil surrounding the crucible can serve        as a sensing device.    -   The invention can be used to process non-ferrous alloys.    -   Aluminum alloys are the preferred charge material for the        generator.    -   The invention can be utilized to process ferrous alloys.    -   Sensing of a process control signal can be accomplished via the        induction heating/cooling coil feedback to the induction power        supply.    -   Sensing of a process control signal can be done via a separate        solenoid coil in proximity to the charge.    -   The equipment and method can control the process used to produce        and hold the material in a manner that a semi-solid charge of        the material can be delivered to a forming device at the desired        fraction solid repeatedly, cycle-to-cycle.    -   The generator can be attached to a multi-axis robot arm to avoid        any in-process material transfers that can introduce        contamination to the charge.    -   The equipment can be directly coupled to a molten metal supply        and/or a metal forming device.    -   The equipment can be utilized in an uncoupled mode to a metal        source and forming device.    -   The metal or metal alloy in the generator can be used to        continuously monitor the solid fraction and/or liquid fraction        of the metal charge.    -   The control system for the generator can be designed to        continuously control the metallurgical condition of the metal        charge to a selected condition in a repeatable fashion.    -   The mixing of the metal charge in the generator can be toroidal        mixing.    -   The uncoupled generator can be enclosed on the top opening so        that an inert gas can be introduced over the metal charge to        limit or prevent oxide generation.

It is one non-limiting object of the present invention to provide anapparatus and method that can determine, monitor and/or control one ormore physical properties of a metal or metal alloy in a crucible orcontainer system via analysis of one or more sensed electricalparameters (e.g., electrical feedback signals obtained from the at leastone induction coil that is positioned at least partially about thecrucible or container system, etc.).

It is another and/or alternative non-limiting object of the presentinvention to provide an apparatus and method that can determine thetemperature, solids fraction, and/or liquid fraction of a metal or metalalloy in a crucible or container system via analysis of electricalfeedback signals obtained from the at least one induction coil that ispositioned at least partially about the crucible or container system.

It is still another and/or alternative non-limiting object of thepresent invention to provide an apparatus and method that can determineand/or control of the temperature of a metal or metal alloy in acrucible or container system via analysis of electrical feedback signalsobtained from at least one induction coil that is positioned at leastpartially about the crucible or container system.

It is yet another and/or alternative non-limiting object of the presentinvention to provide an apparatus and method that can control theprocessing of a metal or metal alloy from the time the metal or metalalloy is deposited in a crucible or container system to the time themetal or metal alloy is poured out of or ejected from the crucible orcontainer system, and wherein at least a portion of the information forsuch processing control is obtained from the analysis of electricalfeedback signals obtained from the at least one induction coil that ispositioned at least partially about the crucible or container system.

It is still yet another and/or alternative non-limiting object of thepresent invention to provide an apparatus and method that can determinethe temperature of a metal or metal alloy in a crucible or containersystem without the use of a thermocouple.

It is another and/or alternative non-limiting object of the presentinvention to provide an apparatus and method that can determine andcontrol the temperature of a metal or metal alloy in a crucible orcontainer system without the use of a thermocouple.

It is still another and/or alternative non-limiting object of thepresent invention to provide an apparatus and method that can determine,monitor, and/or control at least one property of a metal charge in agenerator is subjected to a magnetic field formed by at least oneinduction coil by using a sensing arrangement to directly sense and/orindirectly sense at least one electrical parameter, which at least oneelectrical parameter can be used to at least partially determine a loadresistance inside a region that is at least partially encircled by theat least one induction coil, a resistivity of the metal charge, atemperature of the metal charge, a solid fraction of the metal charge,and/or a liquid fraction of the metal charge.

It is still another and/or alternative non-limiting object of thepresent invention to provide an apparatus and method that includes theuse of a controller to at least partially control a power level to an atleast one induction coil based on at least one sensed electricalparameter.

It is yet another and/or alternative non-limiting object of the presentinvention to provide an apparatus and method that includes the use of acontroller to at least partially controls a reduction of temperature ofa metal charge from a liquidus temperature of the metal charge to atemperature greater than a solidus temperature of the metal charge sothat the metal charge has a certain solid fraction and liquid fractionjust prior to a time the metal charge is poured from or otherwiseejected from a generator.

It is still yet another and/or alternative non-limiting object of thepresent invention to provide an apparatus and method that senses atleast one electrical parameter from feedback from at least one inductioncoil.

It is another and/or alternative non-limiting object of the presentinvention to provide an apparatus and method that senses at least oneelectrical parameter from a solenoid coil in proximity to at least oneinduction coil.

It is still another and/or alternative non-limiting object of thepresent invention to provide an apparatus and method that mathematicallymanipulates (e.g., taking derivatives of parameters, correlating data,curve fitting, etc.) at least one sensed electrical parameter to atleast partially used to determine one or more tends in physicalproperties (e.g., temperature of metal charge over time, resistivity ofmetal charge over time, load resistance encountered by induction coilover time, resistivity of metal charge to power to induction coil,resistivity of metal charge to temperature of metal charge, etc.) of themetal charge.

These and other objects and advantages will become apparent to thoseskilled in the art upon the reading and following of this descriptiontaken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference may now be made to the drawings, which illustrate variousembodiments that the invention may take in physical form and in certainparts and arrangements of parts wherein;

FIG. 1 is a schematic representation of a non-limiting metal castingassembly comprising a semi-liquid metal processing and sensing deviceaccording to the present invention;

FIG. 2 is a schematic representation of the non-limiting semi-liquidmetal processing and sensing device illustrated in FIG. 1, illustratedas a sectional view;

FIG. 3 is a representation of a non-limiting exemplary heat content vs.time curve and an exemplary temperature vs. time curve for a metal ormetal alloy processed in the non-limiting semi-liquid metal processingand sensing device of FIG. 1;

FIG. 4 is a prior art representation of a exemplary resistivity vs. heatcontent curve for a metal or metal alloy processed in the semi-liquidmetal processing and sensing device of FIG. 1;

FIG. 5 is a schematic representation similar to FIG. 2 of thesemi-liquid metal processing and sensing device, illustrating toroidalflow of the molten metal or metal alloy semi-liquid metal processing andsensing device;

FIG. 6 is a prior art representation of a exemplary viscosity vs.temperature curve for a metal alloy charge comprising an A356 gradealuminum alloy having about 7% silicon;

FIG. 7 is a prior art representation of a exemplary temperature vs.solids fraction curve for a metal alloy charge comprising an A356 gradealuminum alloy;

FIG. 8 is a prior art representation of a exemplary family of viscosityvs. shear rate curves for an A356 grade aluminum alloy having differingsolids fractions;

FIG. 9 is a graph illustrating the relationship between temperatureversus resistivity data and temperature versus the total resistance inan induction coil;

FIG. 10 is a graph illustrating the relationship between temperature andthe actual load on the induction coil during a certain time period;

FIG. 11 is a process flow diagram illustrating one non-limiting processarrangement in accordance with the present invention; and,

FIG. 12 is a non-limiting simple process illustration for processing ametal charge in accordance with the present invention.

DESCRIPTION OF NON-LIMITING EMBODIMENTS OF THE INVENTION

Referring now in greater detail to the drawings, wherein the showingsare for the purpose of illustrating various embodiments of the inventiononly, and not for the purpose of limiting the invention, the presentinvention is directed to a SML/SSM processing and sensing device,hereinafter also referred to as a “generator,” for preparing SML/SSM foruse in metal forming or casting operations. In general, the processincludes cooling the metal charge to the liquid, molten metaltemperature of the metal charge after the metal charge has been insertedinto the generator, then further cooling the metal charge in acontrolled manner with electromagnetic stirring and/or other types ofstirring in order to minimize the formation of a dendritic crystallinestructure, and/or to facilitate the formation or nucleation of aspheroid α-particle structure in the metal charge. The rate of cooling,and the condition of the molten metal charge below the liquidustemperature can be at least partially determined by measuring the heatcontent of the molten metal charge. In accordance with one non-limitingaspect of the present invention, the heat content of the molten metaland/or SML/SSM in the generator can be at least partially determinedindirectly by determining the electrical resistivity of the molten metalcharge and/or SML/SSM in the generator by measuring the changingvoltage, current, resistance, and/or power that is reflected in thefeedback of the heating/cooling coil as the condition and temperature ofthe molten metal charge and/or SML/SSM changes in the generator. Inaccordance with another non-limiting aspect of the present invention,the molten metal charge and/or SML/SSM in the generator can be agitatedby exposing the molten metal charge and/or SML/SSM to an alternatingmagnetic field. In accordance with still another non-limiting aspect ofthe present invention, the SML/SSM in the generator can be maintainedwithin a desired temperature range and/or maintained to have desiredphysical properties up to the point of delivery of the SML/SSM to aforming or casting apparatus.

Referring to FIG. 1, a generator 10 according to the present inventionis illustrated. Generator 10 comprises part of a metal casting assembly12 comprising a known furnace 14 (e.g., dosing furnace, etc.) to supplymolten metal. As illustrated in FIG. 1, the motel metal is supplied togenerator 10 by use of a robotic arm assembly 16. As can be appreciated,the molten metal can be supplied to the generator by other oralternative means such as, but not limited to, an automatic ladlingtransfer device, a device to tilt generator 10 to pour out the SLM/SSMcharge, and/or a known forming or casting apparatus to accept theSLM/SSM charge. The use and type of a furnace to melt a metal charge iswell known in the art, thus will not be described in detail herein.Likewise, the formation of a metal charge in a forming or castingapparatus is well known in the art, thus will also not be described indetail herein. Non-limiting types of processing devices that include theuse of a furnace and forming or casting apparatus that can be used inthe present invention are disclosed in U.S. Pat. Nos. 7,169,350;6,991,970; and 6,432,160, all of which are incorporated herein byreference.

Referring to FIG. 2, generator 10 is illustrated as comprising anopen-topped crucible 20 adapted to hold a metal charge 22 of moltenmetal and/or SML/SSM such as, but not limited to, aluminum or analuminum alloy. The crucible has a cavity having a generally circularcross-sectional shape; however, it can be appreciated that othercross-section shapes can be used. The outer shape of the crucible alsohas a generally circular cross-sectional shape; however, it can beappreciated that other cross-section shapes can be used. Thecross-sectional area of the crucible cavity and/or outer shape can beconstant or variable. As illustrated in FIG. 2, the cross-sectional areaof the crucible cavity and the outer shape is tapered, thus varies overthe length of the crucible. The tapered cavity of the crucible has theadvantages of enabling easier cleaning of the cavity and easier removalof the metal charge in the cavity. The tapered outer shape of thecrucible has the advantage of making the crucible easier to replace inthe generator. As can be appreciated, the crucible can have othershapes. The present invention will be described herein with respect toan exemplary aluminum alloy charge, although the invention is alsosuitable for processing other molten materials such as, but not limitedto, ferrous and non-ferrous alloys, precious metals, and the like.

Crucible 20 is generally fabricated of a material having suitablestrength, durability, and thermal properties for the temperatures andmetal charge mass to which the crucible 20 will be exposed. Suitablematerials can include, but are not limited to, graphite, known ceramicor refractory materials, or a combination of metal and graphite orceramic materials. The open end of the crucible 20 can be circumscribedby an annular top flange 32 transitioning to the crucible 20 through anannular refractory cap 34; however, this is not required. The annulartop flange can be provided with a means to close the crucible openingfor the purpose of introducing an inert gas (i.e., nitrogen and/orargon, etc.) so as to inhibit or reduce the formation of oxides in theSLM/SSM material; however, this is not required.

Extending circumferentially around the crucible 20 is a generallywell-known solenoid induction coil 24. As can be appreciated, more thanone coil can extend at least partially around the crucible. In onenon-limiting embodiment, induction coil 24 is cooled internally with acoolant such as, but not limited to, water. As can be appreciated,induction coil 24 can be designed to not be cooled by an internallyflowing coolant. As can also be appreciated, one or more cooling coilscan be positioned about the crucible so as to cool the crucible in oneor more zones and/or one or more heating coils can be positioned aboutthe crucible to heat the crucible in one or more zones; however, this isnot required. Induction coil 24 can include a pair of cooling fluidleads 44, 46. In one non-limiting embodiment, cooling fluid leads 44, 46can include a heavy-duty hose or tubing encasing a copper cable such asused in welding equipment; however, it can be appreciated that coolingfluid leads 44, 46 can be formed in other ways. The tubing, when usedfor cooling fluid leads 44, 46, can comprise copper tubing; however,this is not required. A the cooling fluid can be water W or some othertype of cooling fluid. As illustrated in FIG. 1, a cooling fluidreservoir 48 can be used to maintain the desired amount a cooling fluidflowing through cooling fluid leads 44, 46. A tube 49 can be used tosupply cooling fluid from cooling fluid reservoir 48 to the coolingfluid leads 44, 46 or induction coil about the crucible so as tomaintain a desired amount of cooling fluid circulation through theinduction coil and the cooling fluid leads 44, 46. The cooling fluidleads 44, 46, when used, can be couple or connected to a power supply 42to enable current to be supplied to coil 24; however, this is notrequired. The power supply current through the leads 44, 46 and theinduction coil 24 is alternated at one or more desired frequencies toproduce a magnetic field. Typically, the desired frequencies of thealternating current is a high frequency (e.g., at least about 10 Hz);however, this is not required. The magnetic field created by thealternating current has an effect of heating the metal charge 22 in thecrucible 20. Coolant can be used to circulate through induction coil 24to maintain coil 24 at a selected temperature while the alternatingmagnetic field heats the metal charge 22; however, this is not required.

In another non-limiting embodiment, induction coil 24 is spaced fromcrucible 20. When induction heating coil is spaced from crucible 20, thespacing is generally uniform; however, this is not required.Furthermore, when induction heating coil is spaced from crucible 20, thespacing is generally at least about 0.01 inch, typically at least about0.02 include, more typically less than about 10 inches, still moretypically about 0.05-5 inches, and yet more typically about 0.1-1 inch.Induction coil 24 can be spaced at a uniform distance from the crucibleperimeter with refractory spacers, which facilitate centering of thecrucible 20 within the coil 24; however, this is not required.

In another non-limiting embodiment, the height of induction coil 24 canbe selected to encircle the entire crucible 20, at least partiallyencircle the crucible, and/or extend beyond the top and/or bottom ofcrucible 20. Typically, the height of induction coil 24 is selected toencircle the entire crucible 20 so that uniform heating of the metalcharge in the crucible can be achieved. The height of induction coil 24can be selected to not only encircle the entire crucible 20, but to alsoextend above the top and/or below the bottom of the crucible; however,this is not required. When the height of induction coil 24 extends abovethe top and/or below the bottom of the crucible, the top and bottomextensions can either or both be up to one third the crucible heightabove the top and/or bottom of the crucible. For example, for a six inchcrucible height, induction coil 24 can extend up to two inches above thetop of the crucible and/or up to two inches below the bottom of thecrucible; however, it can be appreciated that the induction coil 24 canbe more than a third of the crucible height above and/or below thecrucible. The extension of the induction coil above the top and/or belowthe bottom of the crucible facilitates in achieving even heating and/oragitation of metal charge 22 at both the bottom and top of crucible 20.

Induction coil 24 can be at least partially encased within a couplingmaterial 26, which material 26 contacts the circumferential perimeter ofcrucible 20. As illustrated in FIG. 2, coupling material 26 can alsocontact the bottom of crucible 20; however, this is not required. Thecoupling material, when used, can comprise a rammed or compacted dryrefractory material, mica paper, a cast-in-place refractory-type cement,or some other refractory-type material suitable for providing thermalcoupling of induction coil 24 with the crucible 20. As can beappreciated, other or additional materials can be used for couplingmaterial 26. The thermal coupling created by coupling material 26enables concurrent heat flow from crucible 20 to the water-cooledinduction coil 24 and/or another coiling coil when used, and to theheating of the crucible 20 and the molten metal charge 22 by theinduction field generated by induction coil 24. As such, coolant flowingthrough the induction coil 24 and/or other cooling coils can be used toprovide cooling of crucible 20 and metal charge 22 through the thermalcoupling of coil 24 and/or other cooling coils, coupling material 26,and crucible 20. In one arrangement, the solenoid induction coil 24 canbe used for both cooling and heating, thus can be used to provide ameans of quickly controlling the temperature, viscosity, and solidsfraction (fs) of metal charge 22 in crucible 20.

The crucible 20 and induction coil 24 can be at least partially enclosedwithin a housing comprising a protective, electrically non-conductiveouter shell 28. The housing, when used, can include an intermediateassembly 30 of phenolic spacers and structure hoards; however, this isnot required. Along the closed end or bottom of crucible 20, a couplingmaterial 26 can be provided with an insulating layer 36, and an end cap38 can be configured to extend over the closed end in contact with outershell 28; however, this is not required.

Referring again to FIGS. 1 and 2, induction coil 24 is electricallycoupled or connected to a variable-frequency power supply 42 such as,but not limited to, a 150 kilowatt, a 480 volt, 3-phase AC input powersupply. In one non-limiting embodiment, a range of output frequencies ofthe AC input power supply that can be utilized is 10-10,000 Hz. Thepower supply can be adapted to operate at a selected frequency, or in asimultaneous, multiple-frequency mode, to enhance agitation and/orstirring for homogeneity and/or to better control of the heating andcooling process. For example, a particular frequency can be selectedwhere the cooling rate of the material is the primary parameter, with asecondary parameter being the agitation of the material to achieve aselected homogeneity. As can be appreciated, other or additionalparameters can be used to select the one or more frequencies generatedby the AC input power supply.

The alternating current in induction coil 24 sets up an electromagneticfield that creates a circulating current in metal charge 22. Thealternating current flow in the coil generates or induces an oppositecurrent flow in the conducting metal charge, and depending on theresistivity of the metal charge, causes the metal charge to heat at afaster or slower heating rate. As an example, for a metal chargecomprising 20 pounds of aluminum, approximately 25 kW of power will besufficient to maintain the aluminum in a molten state. In onenon-limiting arrangement, the 3-phase AC input power can be converted toa DC voltage, and then inverted to a single phase AC power at a selectedfrequency; however, this is not required. The choice of avariable-frequency induction power supply enables the frequency to betailored to facilitate in matching the load. Lower frequencies exert ahigher electromotive repulsive force on the metal charge in thecrucible.

The induction power supply 42 can be controlled by a controller 40comprising a known closed-loop feedback system based upon voltage, powerphase, and/or current feedback; however, this is not required. Theclosed-loop feedback system, when used, can be utilized to maintain themetal charge 22 at a predetermined heat content, fs, and/or viscosity,or a predetermined cooling rate during processing. In one non-limitingembodiment, the control of the system can be based on changes in thephase angle of the voltage and current from the induction coil. Sincethe phase angle is independent of the magnitude of the current and thevoltage, it can provide a reliable signal even when the power is beingmodulated up or down in order to meet a heating and/or cooling profileor ramp.

The induction coil 24 can be instrumented with one or more sensors (notshown). These one or more sensors are typically not connected to theinduction power supply. The one or more sensors can be designed tomonitor one or more electrical parameters such as, but not limited to,current, voltage, power consumption, and/or frequency. From the outputof the one or more sensors, particularly voltage, current, the truepower load resistance on the induction coil, and/or the resistivity ofthe metal charge can be determined through mathematical relationships.These calculations can be performed by formulas programmed into a PLC orother type of device, which in turn is used to control the overallheating and cooling process. The ability to sense the condition of themolten charge from the feedback sensed from the induction coileliminates the need for the typical, sacrificial thermocouples that areused to control most prior art metal working and casting processes.

The following Table 1 sets forth the grades and associated constituentsfor selected commercially-available alloys of aluminum. As Table 1indicates, the constituent proportions can vary between grades andwithin a selected grade, including the proportions of aluminum. Thesevariations will affect the properties of the SLM/SSM, including theliquidus temperature, the solidus temperature, the viscosity at selectedtemperatures, the electrical resistivity at selected temperatures, thesolids fraction at selected temperatures, and the heat content atselected temperatures.

TABLE 1 Composition of Selected Aluminum Alloy Grades Grade 332.0 A413.0319.0 A356.0 A357.2 A360.1 384.0 7050 Detailed Composition Silicon, % 8.5-10.5 11-13 5.5-6.5 6.5-7.5 6.5-7.5  9-10 10.5-12   0.12 Iron, % 1.21.2 1   0.2 0.12 1.3 1   0.15 Copper, % 2-4 0.6 3-4 0.1 0.1  0.6   3-4.5  2-2.6 Manganese, % 0.5  0.35 0.5 0.1 0.05  0.35 0.5 0.1  Magnesium, %0.5-1.5 0.1 0.1 0.2-0.45- 0.45-0.7  0.45-0.6  0.1 1.9-2.6 Nickel, % 0.52-3 — — — 0.5 0.5 1.9-2.6 Zinc, % 1   0.5 1   0.1 0.05 0.4 3   0.08-0.15Tin, % — — — — —  0.15  0.35 — Titanium, %  0.25  0.25  0.25  0.250.04-0.2 — — 0.06 Other 0.5 — 0.5  0.15 0.1   0.25 0.5 0.15Constituents, % Aluminum, % bal. bal. bal. bal. bal. bal. bal. bal.

Generator 10 can be designed to control the cooling of metal charge 22that has been heated to at least the liquidus temperature until themolten metal charge reaches a selected SLM/SSM state, and can then bedelivered to a foaming apparatus for fabrication of a selected product.The cooling of the metal charge can be at least partially controlled bymonitoring the resistivity behavior of the metal charge. This type ofcontrol is based on the principles that a) resistivity of the metalcharge varies with the heat content and/or temperature of the metalcharge, b) the heat content and/or temperature of the metal chargecontrols the solids fraction of the metal charge, and c) the solidsfraction of the metal charge correlates to the viscosity of the metalcharge. Ultimately, it is desired to prepare a SLM/SSM charge having aselected viscosity for a selected forming operation. The selectedviscosity can be identified by the resistivity behavior of the metalcharge as a consequence of the interrelationship of resistivity, heatcontent, solids fraction, and/or viscosity for a selected metal charge.

FIG. 3 illustrates an exemplary heat content vs. time curve 50 and anassociated exemplary temperature vs. time curve 52 for a metal chargeheated at a constant input power and frequency. The temperature curve 52is generally steeply linear up to a first temperature value 60, thesolidus of the charge, characterized by a plateau portion between thefirst temperature value 60 and a second temperature value 64, theeutectic temperature of the charge, characterized by a moderate increaseto a third temperature value 68, the liquidus temperature of the charge,and thereafter generally steeply linear, which represents the alloy inmolten form. Time periods t₁, t₂, and t₃ as represented by referencenumbers 54, 56, 58 respectively as associated with a time period thatthe metal or metal alloy reaches the solidus temperature, the eutectictemperature, and the liquidus temperature, respectively when the metalor metal alloy is exposed to a certain amount of energy. The plateauportion of the curve generally represents the metal charge in a SLM/SSMstate. For instance, A356 grade aluminum alloy having about 7% siliconhas a liquidus temperature of about 612° C. and heat content of about260 cal/gm (i.e., temperature value 68 and heat content 70 at time t₃)and a solidus temperature of about 557° C. and heat content of about 130cal/gm (temperature value 60 and heat content 62 at t₁) and a eutectictemperature of about 572° C. and heat content of about 225 cal/gm(temperature value 64 and heat content 66 at time t₂). The heat contentand temperature can be correlated for a selected metal charge mass of aselected material in generator 10 having a selected configuration.

FIG. 4 illustrates an exemplary resistivity vs. heat content curve 80for a selected metal charge mass of a selected material in generator 10having a selected configuration.

FIG. 6 illustrates an exemplary viscosity vs. temperature curve 82 for ametal charge comprising an A356 grade aluminum alloy having about 7%silicon. An exemplary viscosity range 84 for SLM/SSM processingaccording to the present invention corresponds to an initial temperature(˜630° C.) above the liquidus temperature of 612° C., ending at aSLM/SSM temperature of about 590° C. This corresponds to a finalviscosity of about 4 centipoises.

FIG. 7 illustrates an exemplary temperature vs. solids fraction curve 86for a charge comprising a A356 grade aluminum alloy.

FIG. 8 illustrates a family of viscosity vs. shear rate curves for aA356 grade aluminum alloy having about 70% solids fraction (curve 88),about 60% solids fraction (curve 90), and about 50% solids fraction(curve 92). FIG. 8 illustrates a decrease in viscosity with an increasein shear rate for all the solids fractions.

Referring to FIG. 5, the alternating current not only heats charge 22,but the alternating current can also induce agitation or mixing of metalcharge 22 in crucible 20. The mixing is not circumferential or circularabout a vertical axis within crucible 20. Rather, the mixing action istoroidal, as illustrated by the flow vectors 100. This toroidal motionresults in circulation of metal charge 22 in a vertical direction alongthe inside of the crucible wall both upwardly and downwardly from themid-plane of the charge and returning through the axial center of themetal charge. This toroidal mixing is more efficient in producinghomogeneity of the melt at the interior surface area of the crucible tothe center of the melt at the vertical axis of the crucible thancircumferential mixing which does not circulate material from the edgeto the center, but only in layers about the central axis of thecrucible.

Referring again to FIG. 1, generator 10 and the connecting inductionpower leads 44, 46 are affixed to a multi-axis (typically 3 or moreaxes) robotic or mechanical arm assembly 16. As can be appreciated,generator 10 does not have to be connected to any type of robotic ormechanical arm assembly. For instance, the generator can be mounted on astationary stand, in close proximity to the receiving part (shot sleeve,with or with trough) of the die-casting/injection machine. When theSLM/SSM charge is ready for pouring into the shot sleeve, the generator10 tilts to pour the charge into the shot sleeve, thus eliminating theneed for a robotic device; however; this is not required. The armassembly 16 illustrated in FIG. 1, when used, can be adapted tomanipulate generator 10 to a position to receive a molten metal chargefrom a source 14 such as, but not limited to, a dosing furnace, a metalpump, or a ladle. This position of generator 10 is identified in FIG. 1as position “A.” It is anticipated that the metal charge 22 will havebeen preheated to a temperature at or above the liquidus temperature ofthe metal charge when the metal charge is poured into the generator.After the generator has received the metal charge, the arm assembly 16can be designed to move generator 10 to a delivery point at the formingstation while the SLM/SSM is created; however, this is not required. Atthe forming station, the arm assembly 16 can be designed to tiltgenerator 10 to deliver the metal charge 22 to the forming machine 18,or generator 10 can be adapted with a plunger or piston to inject themetal charge 22 into the forming machine 18. This position of generator10 is identified in FIG. 1 as position “B.” The induction power supply42 can either be an integral part of the arm assembly 16, or locatedremotely. In either configuration, the metal charge 22 can becontinuously processed to ensure that the temperature and viscosity,solids traction, and/or laminar flow conditions of the metal charge aremaintained at selected values. The metal charge in the generator can becontinuously processed by a) monitoring the resistance of the loadsystem and/or the resistivity of the metal charge and/or generator 10,b) adjusting the induction coil power and/or frequency, and/or c)adjusting the flow of coolant through induction coil 24 and/or coolingcoils to cool the metal charge 20 in a highly controlled manner untilthe selected temperature and viscosity of the metal charge 20 arereached as indicated by the resistance and/or resistivity. The SLM/SSMprocessing and sensing device of the preset invention enables precisecontrol of the rate of cooling and/or heating of the metal charge in thegenerator, and the accurate, repeatable determination of when theselected temperature and/or viscosity of the metal charge has beenreached. Because of variations in the metal charge constituents, asillustrated in Table 1, and variations in the operational and structuralconfiguration of generator 10, the relationship between resistivity,metal charge temperature and viscosity is generally determinedempirically. This relationship is based in part on the empiricalrelationship between heat content and solids fraction as illustrated,for example, in FIGS. 3 and 7. The relationship between solids fractionand viscosity of the metal charge, as illustrated, for example, in FIGS.6 and 7, can be derived from analysis of metallurgical samples andexperimental data of a selected metal charge composition.

As briefly discussed above, the temperature and viscosity of the metalcharge 20 in generator 10 can be determined empirically by comparison toresistivity and/or resistance measurements. This empirical relationshipwill now be discussed in more detail. The relationship of the resistanceof the load (RL) of the induction coil to the temperature of the metalcharge 22 in the generator can be based on information that iscalculated by use of empirical methods. The basis of this method is thechange in resistance of the metal charge (e.g., aluminum alloy in thegenerator) as reflected in the feedback response of a powered inductioncoil surrounding the generator. The powered induction coil positionedabout the generator operates at some known alternating frequency (e.g.,10-10,000 Hz, 500-5000 Hz, etc.). Due to the alternating current flow inthe conducting coil turns, an alternating magnetic field is establishedin the vicinity of the coil that induces an opposite current flow in theload material (e.g., metal charge 22 and generator, when the generatoris formed of a conductive material). It is this rapidly changing currentflow induced into the load material that generates heat and alsophysical forces that act upon the load, which, in the present case,cause a toroidal stirring effect in the molten metal charge in thegenerator. For instance, a Lorentz Force acts upon the metal charge inthe generator, which force is derived from Equation F=(J_(x,y)×B). Thisforce represents the repulsion between the applied current creating themagnetic field flux density, B, and the induced current, J, in themolten metal charge.

The induction coil used in the present invention is multi-functionalsince it is designed to both heat the metal charge in the generator andto also regulate the cooling of the metal charge in the generator. Thecooling of the metal charge is accomplished by conduction with internalcoil cooling water via the generator and any intermediate material usedto electrically isolate the induction coil from the metal charge and/orcrucible of the generator. As stated above, the induction coil alsoserves as a source of heat to the metal charge due to the generation ofeddy currents directly in the metal charge from the creation ofalternating magnetic fields, which is the typical application forinduction technology. The simultaneous heating and cooling effects allowfor a precise and instantaneous control of the heating and/or coolingrate of the metal charge in the generator.

An induction system consists of a power supply source, loadmatching/tuning means and coil that acts upon the conducting load. Thetypical low-medium frequency induction power supply (PS) first createsDC power by rectifying incoming 3-phase line power and then by employingan inverter that creates a 1-phase alternating power output. Thisalternating power source, to affect a high efficiency utilization ofpower, must be matched, or tuned to the load to create a resonanceeffect. At resonance in a tuned circuit, a relationship exists betweenthe frequency f, the capacitance C, and the inductance L as follows: Atresonance: f=1/((2p)·(L·C)^(1/2)). When tuned properly, the PS will havean output that will be at a fixed frequency. This reduces the impact offrequency variation on sensing and control. The frequency in aninduction system also establishes the effective depth of the inducedcurrent penetration. The relationship is based on the following formula:Penetration depth/reference depth δ=3160 (ρ/μf)^(1/2) inches; where ρ isthe resistivity of the metal charge, μ is the relative permeability ofthe metal charge, and f is the frequency of the alternating powersource. For non-magnetic materials such as ceramics and non-ferrousmetals, μ=1. Although the actual field penetrates to the center of themetal charge, the induced current density is greatest at the surface ofthe metal charge or generator if formed of a conductive material, anddecays exponentially such that the reference depth accounts for themajor portion of the generated heat in the metal charge.

The magnitude of the voltage output from the PS to the induction coildetermines the current flow in the coil turns. It is this alternatingcurrent that creates the alternating magnetic field. The actual power(kilowatts) at the coil is determined by the voltage, current and thepower factor of the load circuit. The power is represented by thefollowing formula: Pc=Ic·Vc·cos θ; where θ is the phase angle betweenthe AC current and the voltage. The power factor, or phase angle isdependent upon the dynamic interaction of the tuning components, PSfrequency, the induction coil & load material coupling (e.g., geometricrelationship and material properties of the induction coil). At nearresonance in the practical parallel LCR circuit, the load impedance isprimarily governed by the resistance in the transmission lines,induction coil and metal charge and generator if formed of a conductivematerial, thus the capacitance part of the circuit has no pureresistance component. As such, X_(L) and the associated resistance R_(L)comprise the impedance relationship of interest. The portion of thecircuit of interest in this case is the inductive branch of the circuit,at which, the response of the load can be measured. This relationship isgoverned by the following formulas: I_(C)=V/R_(L); P_(C)=I²·R_(L); andtherefore R_(L)=P_(C)/I². As can be appreciated, if the frequency has afixed value, then the only variables that will change are the resistanceof the components that are affected by temperature and geometry, namelythe load system (e.g., @ metal charge crucible and induction coil).

The voltage, current and power all change in response to changes in thematerial properties of the load system (metal charge, crucible andinduction coil). These changes are typically temperature related as theload system heats up or cools down. The particular material property ofthe load system that is affected by temperature at the same time impactsthe electrical characteristics of the load system is the resistivity ρ,which in turn is reflected in the resistance of the load system R_(L).This relationship is represented by the following formula:R_(L)=ρ·(1/A); where l is the length of the load material, and A is thecross-sectional area of the material along length l. A is thus thecross-section of the conducing path, represented by A=δ·h_(L); wherein δis the reference depth. The voltage, current and power are alsosensitive to the amount and shape of the metal charge in the generatoras it relates to the geometric coupling of the induction coil to theload system. Therefore the response of the voltage, current and power ofthe circuit can be used to determine what temperature changes have takenplace in the load system by solving for R_(L) and/or ρ.

Induction coils are commonly made from copper and are water-cooled. Assuch, the temperature changes in the induction coil are minimal; thusits resistivity is relatively stable and can be treated as a constantthereby having little impact on the electrical parameters. The gout orinsulating material that can be used between the induction coil andcrucible of the generator is typically a ceramic mixture that is stableand the resistivity values of such materials are at such a high valuethat they can be considered non-conductors and thus insignificant. Thesame principles can be applied to the crucible of the generator if thecrucible is made from ceramic materials. However, if the crucible is agraphite material that is conductive, the crucible will have aresistivity value that changes with resulting temperature effects. Themetal charge in the generator is not only influenced by conductedtemperatures from the induction coil and generator, but the metal chargealso generates its own internal inductive heat. The heat generated bythe metal charge is dependent upon the operating temperature range ofthe metal charge and the frequency of the alternating magnetic field.The increase in heat generated in a gaphite crucible is approximately0.7% at a constant frequency of 1200 Hz, and over the temperature rangeof 550-650° C. Correspondingly, an aluminum alloy A356 increases itsgenerated heat 39.0% over the same temperature range, with the sameelectrical, heating and physical conditions. Therefore the resistancecontribution of a graphite crucible can be considered a constant overthe temperature range of interest that is cited above. The changes inthe properties (resistivity) of the metal charge in the generator due tothe temperature are reflected in the electrical feedback signalsmeasured at the load coil. In the case of metals and metal alloys, thereare phase transformations that occur during heating of the metal andmetal alloy from a solid to the liquid condition, and also in thereverse cooling mode. The solid melting point (solidus temperature) andthe liquid melting point (liquidus temperature) define the lower andupper temperatures of the melting range of the metal or metal alloy,respectively. In this range for multiphase, nonferrous alloys, thesetemperatures are often difficult to measure accurately and to use forsensing the degree of melting or fraction solid (fs) of the metal ormetal alloy. In addition, most of these measurement methods depend onsensors in direct contact with the molten metal and are prone to damageand degradation over time, such as thermocouples. However, several othermaterial properties change in a more normal or near-linear fashion inthis range which can be translated/correlated to temperature values forthe metal or metal alloy. Some of these material properties are fs,relative heat content (enthalpy) and resistivity of the metal or metalalloy. The relationships between heat content vs. temperature, fs vs.temperature, and resistivity vs. temperature can be used to monitorand/or determine several properties of the metal charge in thegenerator. By sensing the resistance (R_(TOT)) and/or resistivity fromthe electrical feedback of the induction coil, various parameters can bededuced regarding the metal charge in the generator. For example variousinduction principles can be used to sense and consequently control the(slurry) process in an indirect fashion. As such, an induction coil ofone or more windings can be used to sense the electrical reactionresponse of a load independently of the heating/cooling coil. Aseparately wound coil, typically of fine insulated wire, cooled orun-cooled can be placed in close proximity to the load container suchthat it is able to be influenced by the field induce in the load by themain heating/cooling coil; however, this is not required. Thisarrangement is called “eddy current” sensing. The sensing coil can bepowered independently or unpowered and the generated feedback signalscan be used in the same fashion as in the coupled case arrangement asdiscussed above to establish the condition of the load material.

A specific non-limiting process control system in accordance with thepresent invention will now be described. The process control system caninclude the use of an Ajax TOCCO Magnethermic “Coil Monitor” unit, acurrent transducer and potential transformers (PT) for measuringvoltage. A current transducer (CT) can be connected to one of the leadssupplying the 1-phase high frequency power to the induction coil. Theleads from the PT's can be connected directly to the induction coil; oneset across all of the induction coil turns and the other set across halfof the induction coil turns on the bottom half of the induction coil.The signals from the CT and the first PT can be connected as inputs tothe coil monitor unit. As can be appreciated, other configurations canbe used in accordance with the present invention.

The metal charge that is to be introduced into the crucible of thegenerator is maintained in a melting/holding furnace. Thismelting/holding furnace is designed to hold a repeatable and accuratetemperature (±3.0° C.) from a temperature set point. When the metalcharge is inserted into the crucible, the power level of the inductioncoil about the generator (P initial) is such that the metal charge inthe crucible does not immediately begin to cool, and the power level ofthe induction coil is such that it induces forces into the molten metalcharge to cause a toroidal stirring action of the metal charge in thecrucible. The stirring action is believed to be important in creating ahomogeneous melt from the edge of the crucible to the center of themolten metal mass.

The setting for the power from the PS is reduced (P cooling) to theinduction coil to cause the cooling capacity of the load system toovercome the heating capacity of the induction system, thereby causingthe metal charge in the crucible to begin to cool. The metal chargecontinues to be stirred during the cooling process since power is stillbeing applied by the induction coil to the metal charge. During thecooling process, the metal charge begins to cool rapidly from the moltenphase to the semi-liquid/solid phase, thus passing through the liquidustemperature of the metal charge. Since the liquidus temperature is atthe phase transition between the fully liquid/molten metal charge andthe initiation of solidification of the metal charge, solid particles ofhigh melting point constituents begin to nucleate and disperse viastirring into the homogeneous mass. This mass particle nucleation takesplace due to the rapid cooling rate in the presence of the stirring ofthe metal charge. Typically, in molten metal alloy systems, dendriticcrystal growth occurs when the alloy is in contact with a cooledstationary surface, where stirring is not present in the molten metalbath. The formation of dendritic structure thus reduces the ability ofthe material to flow at these temperatures and fs levels, and thusincreases the force required to move the material into a mold to form acast part. In contrast, in the slurry system form by the process of thepresent invention, the creation of individual, free moving, individualpartially rounded particles are beneficial to semi-solid slurry materialflow since they allow the mass to exhibit a lower viscosity thandendritic material and require less force to move the material into amold.

The monitoring of the generator can be accomplished by monitoring thesingle phase, high frequency AC electrical current and voltage feedbackfrom the induction coil and converting the feedback to 0-5 VAC signalsby the CT and PT units. These signals can then be inputted to the AjaxTOCCO Magnethermic “Coil Monitor” unit wherein the signals aremultiplied to provide a true power signal, compared to an apparent powerso as to determine the phase relationship, and then output as scaled0-10 Vdc sigmals for Coil Current (Ic), Voltage (Vc) and true Power(P_(T)). This relationship is set forth by the following two formulas:P_(T)(Ic·Vc)·cos θ, wherein θ is the phase angle between the highfrequency AC voltage and current phasors; and P_(app)=(Ic·Vc), wherein(Ic) and (Vc) are the scalar values of voltage and current at theinduction coil. The output sigmals from the Ajax TOCCO Magnethermic“Coil Monitor” unit can be connected as analog inputs to the SystemProgrammable Logic Controller (PLC). In the control program, themeasured true power seen at the induction coil (P_(T)) is divided by thesquare of the measured value of induction coil current (Ic²). This valueyields a value for R (R_(TOT)=P_(T)/Ic²). The equivalent resistance ofthe load is calculated by the following formula: Req1=Rtot−Rc−Rcr−Rb,wherein Rc is the resistance of the coil, Rcr is the resistance of thecrucible, and Rb is the resistance of the coil buss. The actual loadresistance of the system is calculated by the following formula: RLoad=Reg1/N², wherein N is the number of coil turns of the inductioncoil. The resistivity of the load of the system is calculated by thefollowing formula: ρ1=[(Req1·hl·3160)/(2·π·rl·N²)]²·1/f, wherein hl isthe length of the load, π is the mathematical value of Pi, and f is thecurrent frequency to the induction coil. The (R_(TOT)) value has beenfound to correlate well with the resistivity value ρ (load). Thiscorrelation is illustrated in FIG. 9.

As illustrated in FIG. 9, the R_(TOT) data, which is represented by thelower line, is very similar to and creates a very similar curve as theρ1 data, which is represented by the upper line. Indeed, the resultsmeasured correlate well with the values calculated. The result of thecalculation of the measured values R (R_(TOT)) is a resistance feedbacksignal that is repeatable cycle to cycle and that can be used as acontrol parameter for heating and cooling of the metal charge in thegenerator.

FIG. 10 illustrates the liquidus relationship of the metal charge.Specifically, FIG. 10 illustrates the R_(TOT) and correspondingtemperatures. The behavior of the measured R_(TOT) value as the metalcharge cools in the generator from the liquid phase to the semi-solidregion appears as a slight, negative constant rate of change from ahigher liquid value corresponding to the liquid alloy temperature. Asthe metal charge material cools, it reaches the liquidus temperature,wherein nucleation of solid particles begins to take place. Also at theliquidus temperature, the R_(TOT) value changes from a slight slope to amore pronounced negative slope value. The reason for this is that themetal charge load is cooling from a region of low resistivity change perchange in temperature into a region where the resistivity changes aremore significant per change in temperature. Since the metal charge loadis the only item in the system that is drastically changing, the othercomponents of the process system are either remaining constants or areslightly changing in a generally linear fashion. As such, the measurechanges are primarily due to the metal charge temperature and consequentresistance change.

The use of this “R Load” or “R_(TOT)” signal for control takes place inthe PLC. The calculated “R Load” or “R_(TOT)” signal can be tracked as afirst derivative with respect to time. When the liquid metal charge isinitially poured into the crucible of the generator, the value of thepower to the induction coil is reduced to a predetermined value allowingthe metal charge in the crucible to begin to cool. A few seconds istypically allowed for the signal to stabilize and for the establishmentof the d(R)/dt value and the monitoring of this value. When the metalcharge cools to the liquidus temperature, the temperature rate of changereduces as the material becomes semi-solid. Correspondingly, theresistance signal changes as well. However, the resistance change issuch that the d(R)/dt decreases. This change in resistance at theliquidus temperature can be used in the control scheme as an initialreference point for determining the degree of semi-solid condition, fs,and control requirements; however, this is not required.

The PLC can be programmed to perform an iterative time and magnitudegate check of the signal as the resistance change occurs. This check canfunction as verification that the change seen is real and not a responseto random signal noise (variation). The verified “R Load” or “R_(TOT)”signal can be measured and continues to decrease in value until a presetΔR=(R_(LIQ)−R) is achieved. The preset R value can be chosen asrepresentative of the desired fraction solid of the metal charge for thesubsequent forming operation. As can be appreciated, the value of theresistance feedback, which reflects the temperature/fs, is prone to somedegree of variation during the cooling of the metal charge.

The resulting variation in cycle time of the cooling of the metal chargein the generator will introduce downstream variations in the formingprocess, and consequently introduce potential problems relating to partquality and defects that are formed in the forming machine. A correctionprocess can be performed in the PLC which measures the feedback signaldR/dt and calculates the real projected cycle time and then comparesthis value to the target cycle time. Based on this projected time, a newcooling power level can be determined and entered into the highfrequency power supply. As a result of this correction, a cooling ratethat arrives at the Target Cycle time as the R value reaches the presetR_(TARGET) can be achieved so as to not impede the delivery of the metalcharge from the generator to the forming machine.

An additional active control can be used to assist in achievingrepeatable cycle time, such as a “Hold” segment of the PLC program. Ifthe R_(TARGET) value is achieved before the cycle time window iscompleted, then the program can be designed to perform an internal PIDcontrol with the target value (R_(TARGET)) as a set-point. The controlwill maintain the target R value until the cycle time is complete. Whenthe R_(TARGET) and Cycle Time conditions are satisfied, the signal topour is given to the process system and the tilt mechanism pours thecontents of the generator directly into the receiver or shot sleeve ofthe forming device. The forming device could be a die cast machine(either a horizontal or a vertical unit), gravity semi-permanent moldmachine, sand mold or other configuration. Generally a die cast machineis used which can benefit from the slurry charge control and short cycletimes, which can lead to increased productivity. At the same time asproductivity increases occur, the quality of the product will beimproved by the high fs structure of the slurry material.

Referring now to FIG. 11, there is illustrated a process flow diagramillustrating one non-limiting process arrangement in accordance with thepresent invention. The first step of the control process is to start theprocess cycle. The next step is to set the cooling power level for theinduction coil. The next step is to fill the crucible of the generatorwith a molten metal charge. At the time the crucible is being filledwith a molten metal charge from a furnace, the power level to theinduction coil is sufficient to prevent the temperature of the moltenmetal charge from dropping below the liquidus temperature of the metalcharge; however, this is not required. Generally, the power level forthe induction coil is initially set so there is very little temperaturedrop in the molten metal charge as the molten metal charge istransferred from the furnace to the crucible in the generator. Once thecrucible is filled to a desired level with the molten metal charge, thenext process step illustrated in FIG. 11 is to cool the metal charge inthe crucible to the liquidus temperature of the metal charge. For eachtype of metal or metal alloy that constitutes the metal charge, there isa specific liquidus temperature for such charge. The resistivity of themetal charge at the liquidus temperature is indicated in the flowdiagram as R_(liq). During the cooling process of the metal charge tothe liquidus temperature, the resistance of the load inside theinduction coil (e.g., metal charge plus the crucible, if the crucible isformed of a conductive material) is sensed (R), and can be recorded. The1^(st) derivative of the sensed resistance (R) with respect to time ismonitored The trend of this 1^(st) derivative in the fully molten phaseof the alloy is slightly positive. When the liquidus point of the alloyis reached, the 1^(st) derivative of reflected R trends negative. Thechange in the derivative is verified by the programming of several gateconditions in the PLC which determine beyond any signal noise that theliquidus point has been reached. Once it has been verified that themetal charge in the crucible has reached the liquidus temperature, thesecond stage of the process begins wherein the metal charge is cooledbelow the liquidus temperature, but above the solidus temperature. A newload resistance set point R_(target) is calculated in the controlsystem. A preset value of a ΔR is used along with the R_(liq) todetermine the R_(target). R_(target) is relative to the sensed value ofR_(liq). This new Load resistance set point R_(target) represents acertain temperature for the metal charge wherein the metal charge has acertain solids fraction and liquid fraction that is desirable fordelivery to a casting or forming machine. The power level to theinduction coil can be adjusted or read from the PLC during the secondstage of the cooling of the metal charge so that the metal charge is atthe desired temperature and includes the solids fraction and liquidfraction at the time the metal charge is to be delivered to the castingor forming machine. As such, the power level to the induction coil mayhave to be 1) further reduced to increase the cooling rate of the metalcharge in the crucible, and/or 2) increased to slow the cooling rate ofthe metal charge in the crucible. As can be appreciated, the power levelto the induction coil can be adjusted one or more times during thesecond stage of the cooling of the metal charge so as to meet the targettime the metal charge is to be delivered to a casting or formingmachine. During the second cooling stage the resistance of the inductioncoil load is sensed (R), and can be recorded. The sensed resistance isthen compared to the second resistance set point R_(target). If thedetected resistance R is equal to R_(target), then the metal charge isdetermined to be at the desired temperature and have the desired liquidand solids fraction, thus can be poured into or otherwise deposited intoa casting or forming machine. If the casting or forming machine is notready to accept the metal charge, the process system of the presentinvention can be designed to maintain the metal charge in the crucibleat R_(TARGET) until the casting or forming machine can accept the metalcharge. If the sensed resistance of the induction coil load is not equalto the resistance set point R_(TARGET), the power level to the inductioncoil is decreased, increased or maintained to cause the sensedresistivity R to approach R_(TARGET). Various mathematical techniquescan be used to determine the rate at which the sensed resistance, R isapproaching R_(TARGET) and whether the trend of the sensed resistance Rto R_(TARGET) over time is correct or requires adjustment by changingthe power level to the induction coil. As illustrated in the processflow diagram, the sensed resistance, R is compared to R_(TARGET) untilthe two values are the same. It is intended that the methods ofprogramming the control for this process ideally enable the R_(TARGET)condition of the material to be reached concurrently with the desiredcycle time of the forming machine. Once the metal charge is poured orotherwise deposited into a casting or forming machine, the controlprocess is complete and anew process can be started.

Referring now to FIG. 12, there is illustrated a non-limiting asimplified illustration for processing a metal charge in accordance withthe present invention. The first picture illustrates a molten metalcharge being poured into a crucible of a generator. The temperature ofthe metal charge at this point is above the liquidus temperature. Themanner in which the metal charge is conveyed to the crucible from thefurnace is not limiting. The type of furnace used to melt the metalcharge is also not limiting. Once the metal charge is deposited into thecrucible, the metal charge is stirred and cooled until the metal chargereaches the liquidus temperature of the metal charge. This process stepis the same or similar to the first stage of cooling as discussed abovewith regard to the process flow diagram illustrated in FIG. 11. From thetime that the metal charge is deposited in the crucible to the time thatthe metal charge is removed from the crucible, a process control systemis used to control the cooling rate of the metal charge in the crucible,temperature of the metal charge in the crucible, and solid and liquidfraction of the metal charge in the crucible. One non-limiting exampleof a process control system that could be used is illustrated in FIG.11. This process control system is illustrated as Active Process Controlin FIG. 12. In one non-limiting arrangement, the Active Process Controlincludes the use of (3) preset values for the high frequency power tothe induction coil, namely 1) a preset value at the time the metalcharge is poured into the crucible, 2) a preset value for the coolingcycle of the metal charge in the crucible, and 3) a preset value for themetal charge at the time the metal charge is to be removed from thecrucible. The Active Process Control can include several modes ofoperation. One operation mode is a Cycle Time Target Mode that is usedto identify the cooling rate (dR/dt) after the metal charge has beencooled to its liquidus temperature. The Cycle Time Target Mode isdesigned to change the cooling power to the induction coil to allow theR_(TARGET) to be achieved at same time as the Cycle Time Target. Anotheroperation mode is a Hold Mode. The Hold Mode is designed to allow theR_(TARGET) value to be held constant by varying the cooling power to theinduction coil via a PLC based PID control loop until the Cycle TimeTarget is reached. Another mode is a Charge Level Sensing 1 Mode. ThisCharge Level Sensing 1 Mode is designed to enable a determination of theamount of metal charge in the crucible after being poured into thecrucible. Since the value of “R Load” or “R_(TOT)” is stable andrelatively constant during the liquid phase cooling of the metal charge;the amount of metal charge in the crucible will change the metal chargegeometry such that the “R Load” or “R_(TOT)” signal level can reflectthe amount of metal charge in the crucible. The PLC, based on the levelof “R Load” or “R_(TOT)”, can either accept the metal charge as withinprocess limits, abort the cycle if the metal charge is too much or toolittle material to obtain a repeatable, quality forming operation.Another mode is a Charge Level Sensing 2 Mode. The Charge Level Sensing2 Mode is designed to utilize the same metal charge level sensing logicas the Charge Level Sensing 1 Mode. The Charge Level Sensing 2 Mode isdesigned to make a decision, based on empirical data of dR/dt versusvolume at a given power level and melt temperature, whether to set thecooling power of the induction level up-or-down to project a reasonabletarget time for R_(LIQ) to occur, or the entire Cycle time target tooccur. Another mode is a Melt Temperature Compensation Mode. The MeltTemperature Compensation Mode is designed to determine an initialcooling power level based on the incoming temperature of the liquidmetal charge. If the liquid metal charge is cooler than the set-pointvalue, a proportional power adjustment up will be set to allow R_(LIQ)to occur in an acceptable time window, and the total cycle time to occurin a reasonable time window. This mode keeps all of the other controlmodes from enabling drastic power changes for their compensationactions. One or more of these modes can be used in the Active ProcessControl of the present invention. As can be appreciated, other oradditional control modes can be used in the present invention. Once themetal charge in the crucible is at R_(TARGET) and the fs_(TARGET), themetal charge can be poured or otherwise ejected from the crucible into ashot sleeve or other receptacle of a die cast or forming machine asillustrated in FIG. 12. The metal charge is then formed into a die castpart. The crucible can be refilled with a new molten metal from thefurnace and the Active Process Control can be repeated for the new metalcharge.

As discussed above, generator 10 can be designed to perform one or moreof the following functions:

-   -   Continual sensing or periodic sensing of the condition of the        SLM/SSM beginning with the introduction of the molten metal        charge 22 into generator 10 and ending with the delivery of the        processed SLM/SSM into a forming machine, i.e., a shot sleeve, a        sprue, a funnel, and the like.    -   Control of the cooling, heating, and/or agitation of the SLM/SSM        to ensure that the material delivered to the forming machine is        of repeatable, consistent thermal, micro-structural, and/or        viscous condition.    -   Transfer of the metal charge 22 to a forming device directly        from generator 10 without an intervening container or transfer        step. Generator 10 can be mechanically uncoupled from either the        molten metal source and/or the forming machine; however, this is        not required.

A non-limiting feature of generator 10 is the ability to remotely sensethe condition of the SLM/SSM charge, and/or to control the heatingand/or cooling process based on feedback from the non-contact sensingapparatus, i.e., the induction coil 24. Additionally or alternately, afeedback signal can be obtained from a second, unpowered coil (notshown) in close proximity to the molten metal charge 22. The inductionpower unit can comprise a controller 40 as illustrated in FIG. 1 that isadapted with signal conditioning electronics designed to continuously orperiodically monitor the load from the induction coil and/or unpoweredcoil. In most cases, the load will comprise the induction coil 24 andthe conductive material monitored by the coil 24. The conductivematerial can comprise the SLM/SSM charge 22 in the crucible 20, and canadditionally comprise the crucible 20 itself if the crucible material isconductive, e.g. graphite or metal. In another and/or alternatenon-limiting embodiment, generator 10 can be configured with aninduction coil that is “tapped” at selected locations along its length;however, this is not required. This configuration enables selectedportions of the coil to be selectively energized in order to provide anadditional degree of control to generator 10. Specifically, the portionof the coil energized can be selected based upon the size of the metalcharge, with shorter lengths of the coil energized for smaller amountsof metal charge in the crucible. In yet another and/or alternativenon-limiting embodiment, different generators 10 having different coillengths can be utilized for metal charges of different mass; however,this is not required.

Electrically sensed changes in the load are due to thermal changes andmetallurgical changes in the molten metal charge as it either cools orheats. One of the changes is a resistivity change in the metal chargethat produces a change in the induction coil voltage. This voltage canbe used as a feedback signal to control the heat/cooling process of themetal charge in the crucible. Using the signal conditioning features inthe induction control system, this voltage and/or other availablesignals reflecting the metal charge condition can be used to modulateand control the physical process of cooling, heating, and/or maintainingthe condition of the metal charge in the generator. Many inductioncontrol systems have the added ability to generate and track a signaleven when modulating the power output. Therefore, control of the SLM/SSMprocess can be designed to be continuous, non-contact control system(i.e., no thermocouple required in the metal charge and/or cruciblewall), and/or be capable of adjustment to a desired operating pointwhile delivering the metal charge to the forming station.

Another non-limiting embodiment of the device and its application is theuse of generator 10 in conjunction with other SSM/SLM productionmethods. For example, generator 10 can be operably combined with adevice that can initiate the nucleation process. Generator 10 can beutilized to maintain a homogeneous melt temperature. After nucleation,the nucleated SLM/SSM mixture can be further cooled and maintained atcontrolled delivery conditions by generator 10.

Generator 10 also can be designed to control the delivery of the metalcharge 22 in a carefully controlled condition to the forming station 18.Depending on the design of the forming machine, and its chargereceptacle, generator 10 can either be tilted to pour the metal chargeinto a vertically or horizontally oriented shot sleeve, such astypically used in a die-cast machine, or a low-pressure permanent moldforming device. In a forming process that requires the metal charge tobe highly viscous, similar to an SSM billet, the metal charge can beprocessed in generator 10, and the generator can deliver the metalcharge into a specialized sleeve adapted to receive the more highlyviscous SLM/SSM shaped billet (e.g., cylindrical shaped billet, etc.).Generator 10 can be adapted with bottom-sealed refractory or a metalpiston that can function as a physical plunger to eject the metal charge22 from the crucible 20, and be coupled with a hydraulic cylinder tofunction as an integral shot rod and plunger tip; however, this is notrequired.

Because the generator 10 is induction powered, any unintended cooling orfreezing that might occur in the crucible 20 can be melted out. Theability of generator 10 to heat can also be utilized to prevent theaccumulation of solidified oxide skins or skulls in the crucible 20,which skins and skulls can cause product defects such as pre-solidifiedinclusions. The capability of the Generator 10 to “self clean” withoutthe use of a separate physical contact device is very advantageous.

An alternate non-limiting embodiment of generator 10 is that it can bepart of a fully coupled unit. A coupled generator can be adapted toaccept a metered metal charge though a heated transfer tube directlyfrom a dosing furnace or molten metal pump. The molten metal charge canbe designed to pass through a generator wherein the metal charge iscooled and agitated as in the above-described generator. The inductioncoil can be a single solenoid coil powered by a single frequencygenerator, or triple-wound independent coil supplied by a three phasefrequency induction generator to enhance metal movement through thegenerator portion. The metal charge can be maintained in the generatorportion at a controlled condition. When the process cycle calls forSLM/SSM to be injected, the metal supply device (e.g., pump or dosingunit) is actuated, and the generator portion allows or causes the metalcharge to proceed to a heated conduit and into a forming or injectionchamber as a new volume of molten metal is introduced into the generatorportion. This method is suitable for a dedicated forming station thatproduces SLM/SSM parts exclusively.

The semi-liquid metal processing and sensing device of the presentinvention provides the ability to precisely control the cooling and/orholding process for a metal charge in the generator by cooling rate andend condition, which enables the delivery of a SLM/SSM charge in arepeatable fashion to a forming device, even in the event of a cycledelay or production interruption. This arrangement is a unique featureof generator 10 that is not currently available from prior art SLM/SSMdevices.

Generator 10 can be designed to be relatively easy to operate, and notrequire extensive training, and/or be capable of delivery of repeatable,consistent metal charge to a forming station. The non-contact sensingand control, as well as the ability to fully control the thermalbehavior of the metal charge in the generator enables a highly efficientand effective production process. Generator 10 can be readilyincorporated into a production line, and can be designed to be easymaintained by simply exchanging generator units on the robot arm.

It will thus be seen that the objects set forth above, among those madeapparent from the preceding description, are efficiently attained, andsince certain changes may be made in the constructions set forth withoutdeparting from the spirit and scope of the invention, it is intendedthat all matter contained in the above description and shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense. The invention has been described with reference topreferred and alternate embodiments. Modifications and alterations willbecome apparent to those skilled in the art upon reading andunderstanding the detailed discussion of the invention provided herein.This invention is intended to include all such modifications andalterations insofar as they come within the scope of the presentinvention. It is also to be understood that the following claims areintended to cover all of the generic and specific features of theinvention herein described and all statements of the scope of theinvention, which, as a matter of language, might be said to falltherebetween. The invention has been described with reference to thepreferred embodiments. These and other modifications of the preferredembodiments as well as other embodiments of the invention will beobvious from the disclosure herein, whereby the foregoing descriptivematter is to be interpreted merely as illustrative of the invention andnot as a limitation. It is intended to include all such modificationsand alterations insofar as they come within the scope of the appendedclaims.

1-49. (canceled)
 50. An apparatus for determining, monitoring,controlling, and combinations thereof at least one property of a moltenor semi-molten material that is added to a material container and thensubjected to a magnetic field formed by at least one induction coil,said apparatus including a crucible having a cavity designed to containsaid material, a sensing arrangement for directly sensing, indirectlysensing, and combinations thereof at least one electrical parameter,said at least one induction coil at least partially positioned aboutsaid cavity of said crucible, said sensing of said at least oneelectrical parameter is obtained from i) feedback from said at least oneinduction coil that is spaced from said material, ii) information from asolenoid coil in proximity to said at least one induction coil andspaced from said material, or combinations thereof, said at least oneelectrical parameter used to at least partially determine a loadresistance inside a region at least partially encircled by saidinduction coil, a resistivity of said material, a temperature of saidmaterial, a solid fraction of said material, a liquid fraction of saidmaterial, and combinations thereof.
 51. The apparatus as defined inclaim 50, including a controller to at least partially control a powerlevel to said at least one induction coil based on said sensed at leastone electrical parameter.
 52. The apparatus as defined in claim 51,wherein said controller at least partially controls a reduction oftemperature of said material from a liquidus temperature of saidmaterial after said material has been added to said material containerto a temperature greater than a solidus temperature of said material sothat said material has a certain solid fraction and liquid fraction justprior to a time said material is poured from or otherwise ejected fromsaid crucible.
 53. The apparatus as defined in claim 50, wherein aderivative of said sensed at least one electrical parameter as afunction of time is at least partially used to determine a temperaturetrend over time of said material to control a cooling rate of saidmaterial in said material container.
 54. The apparatus as defined inclaim 52, The apparatus as defined in claim 50, wherein a derivative ofsaid sensed at least one electrical parameter as a function of time isat least partially used to determine a temperature trend over time ofsaid material to control a cooling rate of said material in saidmaterial container.
 55. The apparatus as defined in claim 50, whereinsaid at least one induction coil functions as a heating device, acooling device, and combinations thereof of said material.
 56. Theapparatus as defined in claim 54, wherein said at least one inductioncoil functions as a heating device, a cooling device, and combinationsthereof of said material.
 57. The apparatus as defined in claim 50,wherein said material is pure aluminum or an aluminum alloy, saidaluminum alloy including at least 77.55 weight percent aluminum and atleast two metals selected from the group consisting of copper, iron,magnesium, manganese, nickel, silicon, tin, titanium and zinc.
 58. Theapparatus as defined in claim 56, wherein said material is pure aluminumor an aluminum alloy, said aluminum alloy including at least 77.55weight percent aluminum and at least two metals selected from the groupconsisting of copper, iron, magnesium, manganese, nickel, silicon, tin,titanium and zinc.
 59. The apparatus as defined in claim 56, whereinsaid sensing of said at least one electrical parameter is continuous.60. The apparatus as defined in claim 58, wherein said sensing of saidat least one electrical parameter is continuous.
 61. The apparatus asdefined in claim 50, wherein said at least one induction coil a) atleast partially maintains a constant temperature of said material insaid crucible, b) at least partially increases a temperature of saidmaterial in said crucible, c) at least partially decreases a temperatureof said material in said crucible, or any combination of a, b, and c tocontrol a cooling rate of said material in said material container. 62.The apparatus as defined in claim 56, wherein said at least oneinduction coil a) at least partially maintains a constant temperature ofsaid material in said crucible, b) at least partially increases atemperature of said material in said crucible, c) at least partiallydecreases a temperature of said material in said crucible, or anycombination of a, b, and c to control a cooling rate of said material insaid material container.
 63. The apparatus as defined in claim 60,wherein said at least one induction coil a) at least partially maintainsa constant temperature of said material in said crucible, b) at leastpartially increases a temperature of said material in said crucible, c)at least partially decreases a temperature of said material in saidcrucible, or any combination of a, b, and c to control a cooling rate ofsaid material in said material container.
 64. The apparatus as definedin claim 82, wherein said at least one induction coil at least partiallymaintains a constant temperature of said material in said crucible for aperiod of time, at least partially increases a temperature of saidmaterial in said crucible of a period of time, at least partiallydecreases a temperature of said material in said crucible for a periodof time, and at least partially causes said material in said crucible tobe stirred for a period of time to control said cooling rate of saidmaterial in said material container.
 65. A method of monitoring,determining, controlling, and combinations thereof at least one propertyof a molten or semi-molten material in a material container that issubjected to a magnetic field formed by at least one induction coil tocontrol a cooling rate of said material in said material container, saidmethod including: inserting said molten or semi-molten material in acavity of said material container, said cavity at least partiallyencircled by at least one induction coil; applying power to said atleast one induction coil, said at least one induction coil functions asa heating device, a cooling device, and combinations thereof of saidmaterial; directly sensing, indirectly sensing, and combinations thereofat least one electrical parameter as said power is applied to said atleast one induction coil, said sensing of said at least one electricalparameter is obtained from i) feedback from said at least one inductioncoil, ii) information from a solenoid coil in proximity to said at leastone induction coil, or combinations thereof; and, determining a loadresistance inside a region at least partially encircled by saidinduction coil, a resistivity of said material, a temperature of saidmaterial, a solid fraction of said material, a liquid fraction of saidmaterial, and combinations thereof based at least partially on saidsensed at least one electrical parameter at least while said solidsfraction of said molten or semi-molten material increases while in saidcavity of said material container.
 66. The method as defined in claim65, including the step of using said sensed at least one electricalparameter to at least partially control said material temperature, saidsolid fraction of said material, said liquid fraction said material, andcombinations thereof in said material container.
 67. The method asdefined in claim 65, wherein said material is inserted in said materialcontainer is at a temperature above a solidus temperature of saidmaterial.
 68. The method as defined in claim 65, wherein said materialis pure aluminum or an aluminum alloy, said aluminum alloy including atleast 77.55 weight percent aluminum and at least two metals selectedfrom the group consisting of copper, iron, magnesium, manganese, nickel,silicon, tin, titanium and zinc.
 69. The method as defined in claim 65,wherein said material is at least partially stirred in said materialcontainer by a magnetic field generated by said at least one inductioncoil.
 70. The method as defined in claim 65, including the step of usingsaid sensed at least one electrical parameter to at least partiallycontrol a power level to said at least one induction coil.
 71. Themethod as defined in claim 70, wherein said step of controlling saidpower level is used to control a reduction of said temperature of saidmaterial to a temperature greater than a solidus temperature of saidmaterial so that said material has a certain solid fraction and liquidfraction just prior to a time said material is poured from or otherwiseejected from said material container.
 72. The method as defined in claim65, including the step of continuously or periodically monitoring saidsensed at least one electrical parameter while said material is in saidmaterial container to track a temperature trend of said material in saidmaterial container.
 73. The method as defined in claim 65, including thestep of determining a derivative of said sensed at least one electricalparameter as a function of time and using said derivative to at leastpartially determine a temperature trend over time of said material insaid material container.
 74. The method as defined in claim 65,including the step of setting a target electrical parameter andcontrolling said power level to said at least one induction coil so thatsaid temperature of said material in said material container obtains acertain temperature to cause said sensed at least one electricalparameter to equal said target electrical parameter.
 75. The method asdefined in claim 65, including the step of setting a target cycle timeand controlling said power level to said at least one induction coil sothat said temperature of said material in said material containerobtains a certain temperature in a time period that is equal to saidtarget cycle time, said target cycle time can be a set or adjustablevalue.
 76. The method as defined in claim 65, including the step ofdepositing said material in a forming or casting machine after saidmaterial in said material container has reached a desired temperature,solids fraction, and combinations thereof.